Toggle switch



P. ALlO ETAL Nov. 22, 1960 TOGGLE SWITCH Filed July 10, 1959 FIC-3.3.

FIGS.

INVENTORS PETER ALIO ALBERT s. OAKMAN ATTORN EY United States Patent() T OGGLE SWITCH Peter Alio, Bronx, and Albert S. Oakman, Flushing, N.Y., assignors to Allied Control Company, Inc., New York, N.Y., a 'corporation of New York Filed July 10, 1959, Ser. No. 826,246

8 Claims. (Cl. 20G-67) This invention relates to the art of electric switches and, more particularly, to a toggle switch having "improved structural features and operational characteristics.

A number of presently available toggle switches include a pair of spaced fixed electrical contacts and an electrically conductive rocker device having a pair of arms which are adapted to make contact with the fixed contacts. Rocking movement is imparted to the rocker device by an actuating means whereby each arm makes s eparate contact with its fixed contact depending on the position of the rocker device. The actuating means usual- ICC thereby insuring a proper electrical connection between' these parts at all times.

The primarysobject of this invention is to' provide an improved toggle lswitch of the miniature and sub-miniature types having improved structural features and ops erational characteristics.

ly includes a handle, a slide rod and a spring for yieldl ingly maintaining the slide rod in engagement with the rocker device. The spring is generally of the light duty type, especially in the case of miniature and sub-miniature toggle switches. Such springs are capable of exerting'only sufficient force to maintain the slide rod in contact with the rocker device and effect tiltingA movement of-'the rocker device on operation of the handle under favorable conditions of use.

{'In the event one of the arms of the rocker device becomes stuck to its fixed contact during use, such as lby formation of a Weld area therebetween, the weld frequently cannot be broken by manipulating the handle of the actuating means in the usual manner. Due to the design of conventional toggle switches, the spring thereof permits actuation of the handle but does not break the weld and thereby allow the rocker device to tilt. In other words, although the handle may be moved through its normal operating range, the weld remains intact and prevents tilting of the rocker device in response to. movement ofthe handle. This renders the switch inoperative. Our instant invention overcomes the difficulty discussed above in that it provides an efiicient and dependable toggle switch which can be manufactured at a reasonable cost in miniature and sub-miniature sizes and which is capable of readily breaking a simple weld that may be formed between normally relatively movable contacts without affecting the operation of the switch or -impairing its, usefulness. Our switch also comprises arocker unit and arspring pressed activating mean-s including a handle and a slide rod. The rocker unit and actuating means are so constructed and arranged that, in the event of formation of a weld of the character indicated, normal manipulation of the handle automatically and temporarily converts the actuating means into a rigid and non-yield- Another object of the invention is to provide a toggle' switch including'at least one pair of relatively movable` electrical contacts, the parts being so constructed andarranged that, in the event vsuch contacts become electrically welded to each other during use, the weld may be broken by operating the 'switch in a normal manner without impairing the utility of the switch.

A further object of the invention s to provide miniature and sub-miniature toggle switches which are simple and compact in design, which are sturdy and durable in construction, which are adapted to be readily assembled, which are reasonable in manufacturing costs and which are eficient and dependable in operation. In attaining the enumerated objects, a toggle switch constructed in accordance with this invention preferably includes a housing comprising a base and a cover secured to the base. The base carries a pair of spaced, fixed electrical contacts. Positioned within the housing is a generally U-.shaped saddle consisting of a web which is affixed tothe base and a pair of upstanding arms. Each arm has an end notch. A rocker unit is mounted for rocking movement on the saddle. The rocker unit comprises a' central member and a pair of upwardly vdivergent arms which are adapted to make contact with a corresponding fixed contact'depending on the position of the rocker unit. The central member of the rocker unit rides in the saddle' notches and forms'intimate wiping contact with the por-l tions of the saddle that define the notches. The switch is-'provided with an actuating means lfor` effecting rocking movement of the rocker unit in opposite directions to thereby cause a selected larm of the rocker unit to make contact with a corresponding fixed contact.' The actuating means comprises a tubular handle which extends downwardly through the cover and is pivoted thereto. A rod is slidable in the handle. The rod projects below the handle and bears against the upper surface' of the .rocker unit. A helical compression spring is positioned withinV the handle and normally and'yieldingly urges the rod into engagement, with the rocker unit. The actuating means includes a means limiting upward i movement of the rod relative to the handle. This means ing mechanism which is capable of exerting sucient l the possibility of the rocker unit stopping at dead center, 4

or what is commonly referred to in the art as center OIF-position. This feature is attained by the unique .design and arrangement of the rocker unit and its support.

. Furthermorethe parts are so configured that the roclcer unit makes intimate wiping contact with its support,

may consist of a pin within the confines of the spring and adapted to bear at its ends against the upper end of the rod and the handle. This pin is ineffective when the switch is operating normally. The parts of the actuating means and the rocker unit are so constructed and arranged that,v ,when one arm of the rocker unit makes contact'1.with.a 'corresponding fixed contact and the rod is at 'its upward limit of movement relative to the handle as'a-llowed'by the pin, the distance from the pivotal axis of the handle to part of the other arm which is normally engageable by the rod is less than the distance from such pivotal axis to the lower end of the rod. When the parts are in this relative position, the actuating means becomes, in effect, a rigid and non-yielding device and can be. operated to exert a much stronger force on the rocker unit than' the spring alone. This enables the actuating ineans to coact with the rocker unit in a manner to break a weld of the type discussed earlier herein and allow the rocker unit to be tilted. VTheobjects and advantages of this invention will be readily understood by persons trained in the art from the following detailed description and the accompanyngudrawing which describe and illustrate a preferred toggl'e'switch embodyingth'e invention.

Patented Nov. 22, 1960 In the drawing, wherein like reference numerals identify corresponding parts in the several views:

Fig. 1 is a top plan view of a toggle switch constructed in accordance with this invention;

Fig. 2 is a view in cross-section taken along line 2-2 of Fig. l;

' Fig. 3 is a view in cross-section taken along staggered. line 3-3 of Fig. 2;

Fig. 4 is an isometric view of a rocker unit which is also shown in Figs. 2 and 3; and

Fig. 5 is an isometric view of a modified form of rocker unit.

Referring now to Figs. l through 4 of the drawing, we have illustrated therein a housing, which consists of a base 11 and a cover or casing 12. The base is made of a suitable electric insulating material and is formed with an outer annular recess which is defined in part by shoulders 13. The base is equipped with a plurality of. external electric terminals, namely a central terminal 14 and a pair of end terminals 15 and 16. The terminals 14, 15 and 16 are secured to the base by means of corresponding combined rivets and electrical contacts 14a, 15a and 16a which project into the interior of the housing.

Cover 12 comprises a rectangular tubular member 17 which registers with the annular recess of the base and bears against shoulders 13, as shown in Figs. 2 and 3. The tubular member is equipped with a plurality of` depending tongues (not shov'n) which engage the base and thereby couple the cover to the base. The cover includes a right circular cylindrical tubular extension 18 which is externally threaded as indicated at 20. A pair of, nuts 21 engage threads 20 and serve to maintain the switch in a selected position on a panelboard or other support (not shown). The through opening in extension 18 is defined in part by a. downwardly convergent surface 22 and a rounded second surface 23. The junc ture of member 17 and extension19 constitutes an inner annular shoulder 24.

The illustrated switch includes a U-shaped saddle 25 which, as best shown in Figs. 2 and 3, is disposed in a central recess in base 11. Saddle 25 is electrically conductive and consists of a web 26 and a pair of upstanding arms 27. Each arm has an upper end notch 28 which is preferably generally V-shaped but may be of any other suitable configuration. A combined rivet and electrical contact 14a extends through. web 26 and secures the saddle to thev base. This element also serves asa-lan. electrical connection between thetsaddle and termin 14.

An electrically conductive rocker unit 30 is mounted for rocking or tilting movement on saddle 25. This unit is best shown in Fig. 4 and comprises a central member 31 which includes a pair of spaced, parallel, depending flanges 32. Eachv flange has outwardly projecting lateral extension 33 which is positioned in a corresponding saddle notch 28. Integral with central. member 3l is a pair of upwardly and. outwardly divergent arms- 34 and35. These arms are provided with corresponding electrical contacts` 15b and- 16h. The upper surface of member 31 is planar, as shown in Fig. 4, or may be of any other suitable configuration, other than concave.

Rocking movement is imparted to the rock unit by an actuating means 40 which includes a tubular handle 41. This handle extends through the cover and has an enlarged lower portion 42 which is rounded at 43 for contact with rounded surface 23 of extension. 18 to. permit of pivotal movement of the handle with respect to the cover. Handle 41 is equipped with a finger grip 44 having a. threaded extension 45 which engages a tap in the upper end of the handle. A solid rod 46 is slidable in handle 41 and terminates in a spherical head at its lower end. Rod 46 is made of a suitable metal while head 47 is made of glass or. other appropriate, wear-resistant,

electrical insulating material which is fused to the lower end of the rod. As shown in Figs. 2 and 3, rod head 47 bears against the upper surface of the rocker unit.

Rod 46 is normally and yieldingly maintained in engagement with the rocker unit by a spring means. This means preferably consists of a helical compression spring 48 which is positioned within handle 41 and bears at its ends against the upper end of rod 46 and the free end of cap extension 45. The loading on spring 48 may be adjustedy by turning finger grip 44 to correspondingly move its threaded extension 45.

The switch includes means for limiting upward movement of rod 46 in handle 41. This means preferably consists of a pin 50 that is positioned within the confines of spring 48. This pin is in the nature of a floating pin for the reason that it is slightly shorter than the distance between the lower end of extension 45 and the upper end of rod 46 during normal operation of the spring.

For the purpose of outlining the operation of the form of the invention shown in Figs. 1 through 4, it is assumed that the switch is assembled and that the parts are in the relative position shown in Fig. 2. With the parts so arranged contact 16b makes electrical connection with fixed contact 16a thereby closing a circuit (not shown) through terminals 14 and 16. When handle 41 is pivoted in a clockwise direction relative to the hous ing, as viewed in Fig. 2, rod head 47 rides along the upper surface of the rocker unit, against the action of spring 48, to a position beyond the middle of central member 31. When rod head 47 is in that position, a snap tilting action is imparted to the rocker unit, causing it to swing in a counter-clockwise direction, thereby breaking the connection between contacts 16b and 16a and making contact between contacts 15b and 15a. The central member of the rocker unit' makes intimate wiping contact with the portionsY of the saddle that define notches 28, thus insuring proper electrical connection between these parts at allv times. The parts of the saddle and rocker unit are so arranged as to prevent the switch fromv being maintained on center ofi position by the actuating means.

The pin 50 is of such length as not to affect the action of. rod 46 on the rocker unit under normal operating conditions. In other words, this pin is not in active service under normal operating conditions and rod 46 is subject only to the' force of spring 48.

Pin 50 is brought in active service and cooperates with other parts of the'actuating means to tilt the rocking unit under" certain abnormal conditions. If, for example, the rocker unit is held in the position shown in Fig. 2, due to an electric weld between contacts 16a and 16b, clockwise pivotal movement of the handle will cause rod 46 to move upwardly to the extent that rod 50 bears against cap extension 45 and the upper end of the rod. This converts the actuating means into a rigid, non-yielding de vice. Due to the relationship of the parts of the actuating means and the configuration of the rocker unit, this condition occurs when rod headv 47 has been moved. to the left beyond rocker unit central member 31 and onto its arm 34. At this time, the distance from the pivotal axis of the handle to at least a portion of arm 34 to the left of the member 31 is less than the distance from that axis to the lower end of the rod. Continued clockwise pivotal movement of the handle will cause the rod to exert a non-yielding force of sufficient magnitude on arm 34 to break the weld between contacts 16a and 16b4 and allow the rocker unit to tilt in a counterclockwise direction'. As soon as contact 16b isA freed from contact 16a, rod` 46 is subjected only to the force of spring 48 and pin 50 again becomes inactive.

Fig. 5 illustrates a modified form of rocker unit 51 which is. generally the same as rocker unit 30. Rocker unit. 51, includes. a central member 52 corresponding. to

asesinosto better insure that the rocker unit will not come to rest on dead center or center off position.

From the foregoing, it is believed that the objects, advantages, construction and operation of our present invention will be readily comprehended by persons skilled in the art, without further description. Although the invention has been herein shown and described in simple and practicable forms, it is recognized, that certain parts thereof are representative of other parts which may be used in substantially the same manner to accomplish substantially the same results. Therefore, it is to be understood that the invention is not to be limited to the exact details described herein, but is to be accorded the full scope and protection of the appended claims.

,',We claim:

1. In a toggle switch, a housing comprising a base and a `cover secured to Aand projecting above the base, a pair of spaced, fixed electrical contacts'carried by the' base, a rocker unit within the lhousing and mounted for rocking movement relative to the base, said rocker unit including a pair of arms, said arms being adapted to make electric contact with the fixed contacts separately, and actuating means for effecting rockingmovement of the rocker unit in opposite directions to cause a selected arm thereof to make Contact with a corresponding fixed contact, said actuating r'neans'comprising a handle extending generally downwardly through the cover and movable with respect thereto about a pivotal axis, a rod slidable along the handle, said rod extending below the handle and bearing at its lower end against the rocker unit, spring means carried by the handle and normally and yieldingly urging the rod toward the rocker unit, and means limiting upward movement of the rod relative to the handle, the parts being so constructed and arranged that, when one arm of the rocker unit makes electric contact with the corresponding fixed contact and the rod is at its upward limit of movement relative to the handle, the distance from the pivotal axis to part of the other arm which is normally engageable by the rod is less than the distance from the pivotal axis to the lower end of the rod.

2. In a toggle switch, a housing comprising a base and a cover secured to and projecting above the base, a pair of spaced, fixed electrical contacts carried by the base, a rocker unit within the housing and mounted for rocking movement relative to the base, said rocker unit including a central member and a pair of spaced and upwardly divergent arms carried by the central member, said arms being adapted to make electric contact with the xed contacts separately, and actuating means for effecting rocking movement of the rocker unit in opposite directions to cause a selected arm thereof to make contact with a corresponding fixed contact, said actuating means comprising a handle extending generally downwardly through the cover and movable with respect thereto about a pivotal axis, a rod slidable along the handle, said rod extending below the handle and bearing at its lower end against the rocker unit, spring means carried by the handle and normally and yieldingly urging the rod toward the rocker unit, and means limiting upward movement of the rod relative to the handle, the parts being so constructed and arranged that, when one arm of the rocker unit makes electric contact with 4the corresponding fixed contact and the rod is at its upward limit of movement relative to the handle, the distance from the pivotal axis to part of the other arm which is normally engageable by the rod is less than the distance from the pivotal axis to the lower end of the rod.

3. In a toggle switch, a housing comprising a base and a cover secured to and projecting above the base, a pair of spaced, fixed electrical contacts carried by the base, a rocker unit within the housing and mounted for rocking movement relative to the base, said lrocker unit ncluding a pair of arms, said arms being adapted to electric contact with the fixed contacts separately,'vany l actuating means for effecting rocking movement of the: rocker unit in opposite directions to cause'afjselected arm thereof to make contact with a corresponding fixed,V contact, said actuating means comprising a tubular handlef extending generally downwardly through the cover and movable with respect thereto about a pivotal axis, a rod ,p slidable in the handle, said rod extending below the handle and bearing at its lower end against the rocker unit, springI means within the handle and normally and yieldingly urging the rod toward the rocker unit, and means limiting upward movement of the rod relative to the handle, said last mentioned means comprising a pin which is adaptedI to bear at itslends against the handle and the rod'the' parts being so constructed and arranged that, when 'one arm of the rocker unit makes electric contact with tllxe'j correspondingfixedcontact and therod is at its upward; limit of movement relative to the'handle, the distance from the pivotal axis to part of the other arm which is normally engageable by the'rod is less than the distance-v from the pivotal axis to the lower end of the rod. 1 4. In a toggle switch, a housing comprising a base and a" cover secured to and projecting above the base, a pair of spaced, fixed electrical contacts carriedby the base, a rocker unit within the housing and mounted for rock-jv ing` movement relative tothe base, said rocker` unit in? cluding a central member anda pair of spaced and wardly divergent arms carried by the central member, said arms being adapted to make electric contact with the fixed contacts separately, and actuating means for effecting rocking movement of the rocker unit in opposite directions to cause a selected arm thereof to make contact with a corresponding fixed contact, said actuating means comprising a tubular handle extending generally downwardly through the cover and movable with respect thereto about a pivotal axis, a rod slidable in the handle, said rod extending below the handle and bearing at its lower end against the rocker unit, spring-means within the handle and normally and yieldingly urging the rod toward the rocker unit, and means limiting upward movement of the rod relative to the handle, said last mentioned means comprising a pin which is adapted to bear at its ends against the handle and the rod, the parts being so constructed and arranged that, when one arm of the rocker unit makes electric contaot with the corresponding fixed contact and the rod is at its upward limit of movement relative to the handle, the distance from the pivotal axis to part of the other arm which is normally engageable by the rod is less than the distance from the pivotal axis to the lower end of the rod.

5. In a toggle switch, a housing comprising a base and a cover secured to and extending above the base, a pair of spaced, fixed electrical contacts carried by the base, a saddle comprising a web secured to the base and a pair of spaced arms which project into the interior of the housing, each arm having a notch in its upper end, a rocker unit within the housing and mounted for rocking movement on the saddle, said rocker unit including a central member and a pair of spaced and upwardly divergent arms, said central member projecting into said notches and making wiping contact with portions of the saddle arms which define the notches in response to rocking movement of the rocker unit, said arms of the rocker unit being adapted to make electric contact with the fixed contacts separately, and actuating means for effecting rocking movement of the rocker unit in opposite directions to cause a selected arm thereof to make contact with a corresponding fixed contact, said actuating means comprising a handle extending generally downwardly through the cover and movable with respect thereto about a pivotal axis, a rod slidable along the handle, said rod extending below the handle and bearing at its lower end against the rocker unit, spring means carried by the handle and normally and yieldingly urging the actuators` rod toward the rocker unit, and means limiting upward movement of the roclv relative to the handle, the parts being so constructed and arranged that, whenv one armv of the rocker unit makes electric contact withthe corresponding; fixed contact and therod is at its. upward limit.

of spaced, fixed electrical contacts carried by the base,

a saddle comprising a web secured to the base` and a pair of spaced arms which project into the interior of the housing, each armhaving a notch in its upper end, a rocker unit within the housing and mounted for rocking movement on thev saddle, said rocker unit. including a central' member and. a pair of. spaced. and upwardly divergentarms, said central member projecting into said notches and making wiping contact with portions of the saddle arms which define. the notches ink response to rocking movement of the rocker unit, said arms of the rocker unit being adapted to make electric contact with the fixed contacts separately, and actuating means for effecting rocking movement of the rocker unit in opposite directions `to cause a selected arm thereof to make contact with a corresponding fixed contact, said actuating means comprising a tubular handle extending generally downwardly through the cover and movable with respect thereto about a pivotal axis, a rod slidable in the handle, said rod extendingibelow the handle and bearing at its lower end against the rocker unit, spring means within the handle and normally and yieldingly urging the rod toward the rocker unit, and means limiting upward movement of the rod relative to the handle, said last mentioned means comprising a pin which is adapted to bear at its ends againstthe. handle and the rod, -the parts being so constructed and arranged that, when one arm of the rocker unit makes electric contact with the corresponding xed contact and. the rod is at its upward limit of movement relative to. the handle, the distance from the pivotal axis to part of the other arm of the rocker unit which is normally engageable by the rod is less than the distance from the pivotal axis to the lower end of the rod.

7. A toggle switch according to claim 6 wherein at least the portion of the upper surface of the rocker unit central member that is normally engageable by the rod is planar.

8. A toggle switch according to claim 6 wherein at least the portion of the upper surface of the rocker unit central member that is normally engageable by the rod is curved upwardly.

No references cited. 

